SAFETY OF HYDROGEN POWERED INDUSTRIAL TRUCKS, LESSONS LEARNED AND EXISTING CODES AND STANDARDS GAPS ICHS Conference – Sept 2011 Aaron Harris -

Agenda Industrial Trucks Codes and Standards Safety Challenges - Intro to FC powered Ind. Trucks - Intro to C&S for Ind. Trucks - Fundamental safety aspects Comparison: Cars and Forklifts Lessons Learned and Gaps - How do they compare with cars? - Where to go from here?

Hydrogen meets the end-user’s goals: - Increase productivity - Optimize floor space - Optimize energy costs - Improved corporate image Hydrogen meets the end-user’s goals: - Increase productivity - Optimize floor space - Optimize energy costs - Improved corporate image Proven fuel cell advantages: - Refueling vs. Recharging - Replace indoor battery charger with outdoor On-Site generation and storage - On-Site Generation = on-demand generation - “Green”, Retail brand names associated with national energy/security policies Proven fuel cell advantages: - Refueling vs. Recharging - Replace indoor battery charger with outdoor On-Site generation and storage - On-Site Generation = on-demand generation - “Green”, Retail brand names associated with national energy/security policies ~1500 vehicles ~300,000 refueling events per year ~1500 vehicles ~300,000 refueling events per year

Component Introduction 1.Onsite Hydrogen Generation 2.Outdoor Compression and High Pressure Storage 3.Indoor Dispensing 4.Battery replacement in existing electric forklifts

Safety Challenges  Struck By and Crush Hazards  Tip over  Regenerative Braking  Distraction  Flammable Gas Release  Battery Room vs. On board FC system  Indoor Fueling  Hot Surfaces  Exhaust  Release of Hazardous Energy  High Pressure Gas  Electric Circuits greater than 50V Industrial Trucks associated with 57 fatalities in 2009.

Fuel Cell System Components Energy Storage – Batteries, Ultra-Caps Power Conditioning Electronics Regenerative Braking Dissipation H2 Detectors/ Proof of Ventilation Fuel Cell Stack and BOP Heat Exchangers Embedded Controls and Software Fuel Cell Power System UL 2267 IEC Codes and Standards –Ind. Trucks Indoor Dispenser Refueling Guidelines HPIT 2 and SAE J Vehicle NFPA 505 UL 2267 UL 583 ITSDF B56.1 Industrial Vehicle 350 Bar Fueling Receptacle/Nozzle Pair SAE J2600 Fuel Cell Power System (Battery Replacement) Hydrogen Pressure System Components CSA HPIT 1 - Cylinders, v alves, fittings, tubing Tank Hydrogen Pressure System SAE J2919 Dispenser Component Standards HGV Dispenser HGV Hose HGV Breakaway HGV Priority and Sequencing HGV Manual Valves HGV Automated Valves Generator NFPA 2 H2 Quality – SAE, ASTM ISO ,2 Installation NFPA 2 NEC ASME HGV 4.10 ISO Compression and Storage NFPA 2 ASME BPVC - storage HGV 4.8 – compressors

Comparison of Cars and Forklifts Automotive Hydrogen Use Million new cars/year kg storage, 300 miles/fill, 1-2 fills/week… kg per week per vehicle kg/day kg in 25 year life / vehicle - Current US Vehicle Fleet: vehicles Automotive Hydrogen Use Million new cars/year kg storage, 300 miles/fill, 1-2 fills/week… kg per week per vehicle kg/day kg in 25 year life / vehicle - Current US Vehicle Fleet: vehicles Industrial Truck Hydrogen Use Million new industrial trucks/year kg storage, fills/week… - 40 kg per week per vehicle kg/day – 6000 kg in 10 year life/vehicle - Current US Vehicle Fleet: vehicles Industrial Truck Hydrogen Use Million new industrial trucks/year kg storage, fills/week… - 40 kg per week per vehicle kg/day – 6000 kg in 10 year life/vehicle - Current US Vehicle Fleet: vehicles FunctionIndustrial TruckLight Duty Vehicle Storage8hr Shift300 miles PowerPeak powerOptimized (idle and peak) WeightHeavy is goodLight is good HybridReplaces batteryReplaces engine Operational Life <10yrs20yrs EnvironmentIndoors (freezers)Outdoors User InterfaceSeparateIntegrated System Pressure250 or 350 bar700 bar

Similarities Engineering Development - fuel cell/battery hybrid vehicle systems, high-pressure hydrogen storage, regenerative braking, “Fuel Cell Range Extenders” Safety - storage vessel performance, leak detection strategies, impact detection strategies, refueling Codes and Standards Gaps – end of life control, aftermarket, consumer product vs. industrial use Similarities Engineering Development - fuel cell/battery hybrid vehicle systems, high-pressure hydrogen storage, regenerative braking, “Fuel Cell Range Extenders” Safety - storage vessel performance, leak detection strategies, impact detection strategies, refueling Codes and Standards Gaps – end of life control, aftermarket, consumer product vs. industrial use ‘Niche’ to ‘Broad’ Market Comparison Differences Engineering Development - weight, tank size and pressure, power requirements, vehicle integration, indoor fueling Safety – driver training, regulatory agency Codes and Standards Gaps – use type 1 tanks, indoor refueling standards Differences Engineering Development - weight, tank size and pressure, power requirements, vehicle integration, indoor fueling Safety – driver training, regulatory agency Codes and Standards Gaps – use type 1 tanks, indoor refueling standards

Fuel Cell System Components SAE J2615 – System Performance SAE J2572 – Fuel Consumption Measurement SAE J2574 – General Vehicle Safety SAE J2617 – Stack Performance SAE J2574 – Design for Recycling PEM stacks Codes and Standards - Automotive Station Refueling Guidelines SAE J2601 Automotive Generator NFPA 2 H2 Quality – SAE, ASTM ISO ,2 Dispenser Component Standards HGV Dispenser HGV Hose HGV Breakaway HGV Priority and Sequencing HGV Manual Valves HGV Automated Valves Installation NFPA 2 NEC ASME HGV 4.10 ISO Compression and Storage NFPA 2 ASME BPVC - storage HGV 4.8 – compressors Interface Standards HGV 4.3 – Temperature Comp. CAFCP Standard H2 Quality Measurement Weight and Measures Tank Hydrogen Pressure System SAE J2579

Fuel Cell System Components Energy Storage – Batteries, Ultra-Caps Power Conditioning Electronics Regenerative Braking Dissipation H2 Detectors/ Proof of Ventilation Fuel Cell Stack and BOP Heat Exchangers Embedded Controls and Software Fuel Cell Power System UL 2267 IEC Codes and Standards –Ind. Trucks Indoor Dispenser Refueling Guidelines HPIT 2 and SAE J Vehicle NFPA 505 UL 2267 UL 583 ITSDF B56.1 Industrial Vehicle 350 Bar Fueling Receptacle/Nozzle Pair SAE J2600 Fuel Cell Power System (Battery Replacement) Hydrogen Pressure System Components CSA HPIT 1 - Cylinders, v alves, fittings, tubing Tank Hydrogen Pressure System SAE J2919 Dispenser Component Standards HGV Dispenser HGV Hose HGV Breakaway HGV Priority and Sequencing HGV Manual Valves HGV Automated Valves Generator NFPA 2 H2 Quality – SAE, ASTM ISO ,2 Installation NFPA 2 NEC ASME HGV 4.10 ISO Compression and Storage NFPA 2 ASME BPVC - storage HGV 4.8 – compressors

Lessons Learned and Gaps  No one would want to put a steel tank on a vehicle  Forklifts use batteries as the counterweight = steel tanks are feasible  Steel tanks: low tech, low cost, fast fill w/o strict temp compensation  Niche markets will not grow faster than automotive  Cars  Forklifts  Refueling cycles are not a concern  Cars = 1800 cycles in 20 years  Forklift = 10,000 cycles in 10 years  Refueling standards are sufficient for all vehicles  Indoor Fueling  Use of the same nozzle/receptacle

Lessons Learned and Gaps User Interface Guidance for user interfaces Regenerative Braking Regenerative braking requirements Conversion Kit Coordinate standards for “conversion kit” for battery replacement Drive Off Refueling “drive off “ prevention – approx. 1 event per 200,000 fuelings Leak and Pressure Testing Consistent approach to leak and pressure testing – assembly and service

Lessons Learned and Gaps Escapee Scenario  Use of SAE J2600 Nozzle/Receptacle for two separately regulated markets  Forklift refueled at retail gas station  Car refueled at warehouse or industrial truck fleet fueling station Cylinder Handling Design and manufacture only as good as the installation Counting Fill Cycles Cyclic fatigue concerns requires close monitoring of fill cycles on each tank Decommissioning Tanks At End of Life Regulation and the aftermarket

Open Market Items Government Policy/ Codes and Standards Interaction - Regulatory Parent Agencies and Involvement - Industrial Trucks – OSHA – Dept of Labor - Automotive - FMVSS – Dept of Transportation Codes and Standards Harmony and Implementation - Harmony - UL 583, UL 2267 and NFPA Implementation – Comprehensive revision to UL2267 to reflect industry standards - Implementation – Interpretation issues with “new” separation distance tables in NFPA Certification and Customer Confidence - Certification path not yet clearly defined - Hurdle for small companies to pursue certification of not yet proven product - Difficult for customers to trust uncertified products - Less diverse customer base (not as many enthusiasts) - Customers need gentle nudge to field new technology

F U E L C E L L S EXPERIENCE The Future of Energy ®